U.S. patent number 7,266,956 [Application Number 11/133,422] was granted by the patent office on 2007-09-11 for base pan and cabinet for an air conditioner.
This patent grant is currently assigned to American Standard International Inc.. Invention is credited to Danny D. Beaver, Billy W. Norrell.
United States Patent |
7,266,956 |
Norrell , et al. |
September 11, 2007 |
Base pan and cabinet for an air conditioner
Abstract
An air conditioner includes an outdoor section comprising an
outdoor coil, a fan, and a refrigerant compressor housed within a
cabinet. The cabinet includes an outer wrapper supported by a
plastic base. The base and wrapper include features that facilitate
the cabinet's assembly and shipping, enhance its appearance, and
ensure its functional and structural integrity. For example, the
base includes breakaway shipping tabs, lead-ins that help guide the
wrapper and coil into position during assembly, and snaps that help
hold the wrapper in place with a minimal number of screws. The
wrapper includes watertight screw-receiving dimples for mounting
electrical hardware, side panels that interconnect by way of a
novel vertically sliding fit, and a spacer for protecting the coil
from being crushed by the wrapper. A frame that supports the fan
also supports the cabinet's top cover.
Inventors: |
Norrell; Billy W. (Panama City
Beach, FL), Beaver; Danny D. (Tyler, TX) |
Assignee: |
American Standard International
Inc. (New York, NY)
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Family
ID: |
29549218 |
Appl.
No.: |
11/133,422 |
Filed: |
May 19, 2005 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20050204767 A1 |
Sep 22, 2005 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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10156560 |
May 24, 2002 |
6705105 |
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10719437 |
Nov 21, 2003 |
6912766 |
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Current U.S.
Class: |
62/125;
62/298 |
Current CPC
Class: |
F24F
1/18 (20130101); F24F 1/38 (20130101); F24F
1/46 (20130101); F24F 1/50 (20130101); F24F
1/56 (20130101); F24F 1/58 (20130101); F25B
39/04 (20130101); F28F 9/00 (20130101); F24F
2013/207 (20130101); Y10T 29/49876 (20150115); Y10T
29/49826 (20150115) |
Current International
Class: |
F25B
49/02 (20060101) |
Field of
Search: |
;62/298,508 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Tapolcai; William E.
Attorney, Agent or Firm: Beres; William J. O'Driscoll;
William
Parent Case Text
This is a divisional application of U.S. patent application Ser.
No. 10/156,560, filed May 24, 2002, which issued as U.S. Pat. No.
6,705,105, and a first divisional U.S. patent application Ser. No.
10/719,437, filed Nov. 21, 2003 now U.S. Pat. No. 6,912,766.
Claims
We claim:
1. An outdoor unit for an air conditioner comprising: a base, said
base being fabricated from an engineered material; a wrapper, said
wrapper being disposed above said base; a top, said top being
disposed on said wrapper, said base, said wrapper and said top
cooperating to define a cabinet having an interior and an exterior;
a heat exchanger, said heat exchanger being disposed in the
exterior of said cabinet; a compressor, said compressor being
disposed interior of said cabinet; and a radio frequency
identification device, said radio frequency identification device
being disposed in said outdoor unit.
2. The outdoor unit according to claim 1 wherein said radio
frequency identification device is embedded in said base, is
self-powered and contains information relating to said outdoor
section.
3. The outdoor unit according to claim 2 further comprising a query
device, said query device triggering said radio frequency
identification device to transmit information contained in said
radio frequency identification device.
4. The outdoor unit according to claim 2 wherein the information
contained in the radio frequency identification device is specific
to the particular outdoor unit of which the base pan in which said
radio frequency identification device is embedded is a
component.
5. The outdoor unit according to claim 2 wherein said radio
frequency identification device contains information relating to
the manufacture and assembly of said outdoor unit.
6. The outdoor unit according to claim 2 wherein said radio
frequency identification device contains information that assists
in the servicing of said outdoor unit.
7. The outdoor unit according to claim 3 wherein said query device
is disposed in a location in the manufacturing facility in which
said outdoor unit is assembled, said location enabling said query
device to trigger said radio frequency identification device as
said outdoor unit proceeds through its assembly process.
8. The outdoor unit according to claim 3 wherein said query device
is located in a position close enough to the location where said
outdoor unit is installed in its end use location to trigger the
transmission of information by said radio frequency identification
device.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to a cabinet for an outdoor section
of an air conditioner, and more specifically to a cabinet with
features that facilitate its manufacturing and assembly.
2. Description of Related Art
Air conditioners, including heat pumps, often include an indoor
section with an indoor heat exchanger for cooling or heating the
interior of a building and an outdoor section with an outdoor heat
exchanger for exchanging heat with the outside air. The two heat
exchangers are part of closed loop refrigerant circuit that also
includes a compressor and an expansion device, which compress and
expand the refrigerant respectively. As the refrigerant moves
through the circuit, its direction of flow determines whether the
indoor heat exchanger cools or heats the air inside the
building.
A typical outdoor section of an air conditioner includes a cabinet
that supports and shelters numerous components, such as the
compressor, various electrical components, the outdoor heat
exchanger, and a fan for drawing outside air through the heat
exchanger. The compressor relies on the base of the cabinet for
structural support; the electrical components need to be sheltered
from rain and snow; and the fan and heat exchanger need structural
support, exposure to outside air, and protection from the weather
and physical impact. Moreover, the cabinet should be readily
manufacturable and provide convenient access to any components
requiring service or repair. Providing a cabinet that effectively
serves all these needs without compromise can be challenging.
Nonetheless, many efforts to provide such a cabinet have been made
with some success.
For example, U.S. Pat. No. 5,294,195 discloses an outdoor cabinet
that houses electrical components at the top of the cabinet. A
small cover can be opened or removed for providing ready access to
the electrical components underneath. However, the edges of the
cover, being exposed along the top of the cabinet, create a
generally unsheltered seam that may leak or may be difficult to
seal against rain and snow.
Another cabinet for an outdoor section of an air conditioner places
its electrical components in a compartment underneath the cabinet's
top cover, as disclosed in U.S. Pat. No. 4,153,310. To accommodate
various models of air conditioners, the compartment has numerous
fastener and passage openings for installing various combinations
of components. However, having some openings left open for some
models may allow moisture to leak into the compartment from other
areas of the cabinet that may be more exposed to outside air.
Some cabinets include features that enhance various functions of
the cabinet's base. For example, U.S. Pat. No. 4,471,633 discloses
a non-corrosive plastic base with integrally formed mounting pads
that can support various size compressors and other components. It
also includes means for handling condensate. Other cabinet bases
that include special features for draining condensate are disclosed
in U.S. Pat. Nos. 4,748,827 and 4,748,828. In U.S. Pat. No.
5,306,121, a cabinet base is shown having a novel means for
mounting the compressor. An intermediate plate between the
compressor and the base includes elastic isolators both above and
below the plate to avoid transmitting compressor vibration to the
base.
Another outdoor cabinet, disclosed in U.S. Pat. No. 6,168,248,
discloses a plastic base with positioning cleats that help align
the side panels, or sheet metal wrapper, to the base. Once in
position, a series of screws fasten the side panels to the side of
the base. Each of the outer side panels has an L-shape to extend
the length of two sides of the base. L-shape panels may simplify
assembly; however, later servicing may be more difficult, as
technicians may have to fully uncover two sides of the outdoor
cabinet even in situations where access to only side is needed.
Moreover, many of screws for fastening the wrapper to the base are
along the lower edge of the cabinet. Such a location may be awkward
to reach once the cabinet is installed outside at generally ground
level.
SUMMARY OF THE INVENTION
To facilitate the assembly and later servicing of an air
conditioner's outdoor section, it is an object of the invention to
provide a cabinet that can be assembled with a minimal number of
fasteners.
Another object is to provide a cabinet whose base includes snap-in
elements that help hold the cabinet's wrapper to the base.
Another object is to provide a base with a raised peripheral rim
that helps hold the cabinet's wrapper in position.
Yet, another object is to provide the base with wrapper lead-ins
that help properly position the wrapper against the raised
peripheral rim.
A further object is to provide a cabinet's base with upwardly
protruding lead-ins that help guide a heat exchanger coil into
position as the coil is being lowered onto the base.
A still further object is to provide a cabinet wrapper with side
panels that interlock by way of a sliding connection between
adjacent panel members.
A still further object is to provide side or corner panels with a
series of dimples that enhance the holding power of the sliding
connection between adjoining panel members.
Another object is to provide an assembly sequence for the cabinet
such that each panel member helps hold its adjacent panel members
in place, yet the panel members can be installed and removed
individually.
Another object is to provide certain panel members of a cabinet
with screw-receiving dimples at various locations. Each dimple can
serve as a pilot hole for inserting a screw for mounting various
electrical components. The dimples are watertight, so if any are
left unused, they can inhibit water from entering the area where
the electrical components are installed.
Another object of the invention is to provide an air conditioner
cabinet with a spacer that helps hold the cabinet's wrapper spaced
apart from a heat exchanger coil contained inside the cabinet.
Yet another object is to provide such a spacer with an anchor that
allows the spacer to hold itself to the coil of a heat exchanger.
The anchor may allow infinite repositioning of the spacer.
Another object is to provide an air conditioning cabinet with a fan
frame that not only supports the frame, but also helps support the
cabinet's top cover.
Another object is to provide the base of an air conditioner cabinet
with breakaway shipping tabs. When shipping the unit, the tabs help
hold the cabinet to a shipping pallet. Later, the tabs can be
severed to readily remove the cabinet from the pallet.
These and other objects of the invention are provided by an outdoor
section of an air conditioner that includes a wrapper mounted to a
plastic base. To facilitate the assembly or servicing of the air
conditioner, the base may include one or more features such as
wrapper or coil lead-ins, a raised peripheral rim to hold the
wrapper, snaps rather than screws to anchor the wrapper to the
base, and breakaway shipping tabs. The wrapper may also include one
or more features such as interconnecting sliding seams; watertight
dimples for receiving screws; or a sequence of assembly that allows
the wrapper's panels to support each other, yet allows the panels
to be installed and removed individually.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cutaway front view of an outdoor section of an air
conditioner according to one embodiment of the invention.
FIG. 2 is a top view of the outdoor section of FIG. 1, but with an
upper portion and one shipping tab removed.
FIG. 3 is a cross-sectional view taken along line 3-3 of FIG.
2.
FIG. 4 is a cross-sectional view taken along line 4-4 of FIG.
2.
FIG. 5 is a cross-sectional view taken along line 5-5 of FIG.
2.
FIG. 6A is a cross-sectional view taken along 6A-6A of FIG. 5.
FIG. 6B is similar to FIG. 6A but of an other embodiment.
FIG. 7 is a top view of a side panel and a corner panel.
FIG. 8 is a cross-sectional view taken along line 8-8 of FIG.
7.
FIG. 9 is a top view of a wrapper/coil spacer.
FIG. 10 is a front view of the spacer of FIG. 9.
FIGS. 11-18 show one possible assembly sequence of the wrapper as
viewed from the top.
FIG. 19 is a front view of a side panel being slid downward into
position between two corner panels.
FIG. 20 is a top view of a fan, fan frame, and a fan orifice
member.
FIG. 21 is a cross-sectional top view showing how a watertight
dimple is formed and how a screw is subsequently installed through
it.
FIG. 22 is a front view of an outdoor section being removed from a
shipping pallet.
FIG. 23 is a perspective view of control box corner panel latching
arrangement in the outdoor suction of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a cutaway view showing the basic components of an outdoor
section 10 of an air conditioner. The term, "air conditioner"
refers to any apparatus (including, but not limited to heat pumps)
for cooling and/or heating a comfort zone, such as a room or area
within a building. In this case, outdoor section 10 includes a
cabinet 12 containing a refrigerant compressor 14, an outdoor heat
exchanger coil 16, and a fan 18. Through lines 20 and 22, a
conventional closed loop refrigerant circuit connects compressor 14
and outdoor coil 16 to the air conditioner's indoor section, not
shown, which may include an indoor heat exchanger coil associated
with a blower for delivering cooled or heated air to the comfort
zone. Whether the indoor coil is used for heating or cooling
depends on the configuration of the particular refrigerant circuit,
and more specifically, the sequence through which the refrigerant
flows through the indoor coil, outdoor coil 16, compressor 14, and
an expansion device (e.g., an expansion valve, capillary tube, or
similar flow restrictor).
The primary focus of the invention pertains to cabinet 12 of
outdoor section 10. Referring to FIGS. 1 and 2, cabinet 12 includes
a base 24 and a wrapper 26. Base 24 is preferably fabricated from
an engineered material such as polypropylene, ABS or polycarbonate.
Wrapper 26 comprises several interconnected sheet metal panels,
such as side panels 28, 30, 32 and 34 and corner panels 36, 38, 40
and 42. Wrapper 26 and base 24 include numerous features that
facilitate the cabinet's assembly, enhance its appearance, and
ensure its structural and functional integrity.
For example, referring to FIGS. 1-3, base 24 includes several coil
lead-ins 44 that each has an inclined surface 46 for guiding a
lower surface 48 of coil 16 into its proper position on coil ramp
49 of base 24 during assembly. Lead-ins 44 extend integrally from
base 24, such that base 24 and lead-ins 44 comprise a unitary piece
for ease of manufacturing.
Referring further to FIG. 4, coil 16 is preferably a helically
wound coil. Lower surface 48 of coil 16 sits on a helical coil ramp
49 that rises off of base 24 and is preferably integral therewith.
In that regard, first end 49a of coil ramp 49 is essentially flush
with the surface of base 24 and helically increases in height in a
direction toward end 49b of the coil ramp. The helical ramping of
coil ramp 49 accommodates the helical wind of coil 16 with the
result that coil 16 is stable and sits vertically on base 24.
Base 24 also includes several wrapper lead-ins 50 that each has an
curved surface 52 for guiding a lower edge 54 of wrapper 26 into
its proper position on base 24 and up against or at least adjacent
to a raised peripheral rim 56. Wrapper lead-ins 50 are also
integrally formed with base 24 to comprise a unitary piece.
Several alignment tabs 58 provide further alignment of wrapper 26
to base 24, as shown in FIGS. 2 and 5. Each alignment tab 58
extends integrally from base 24 and is adapted to engage a slot 60
in a side panel of wrapper 26. Thus, lead-ins 50, alignment tabs
58, and rim 56 all help to ensure that the side panels and the
totality of wrapper 26 are installed in their proper position and
relationship relative to base 24.
To reduce the use of conventional threaded fasteners, a number of
catches 62 integrally extending from peripheral rim 56 of base 24
help secure wrapper 26 in place, as shown in FIGS. 2, 5 and 6A.
Each catch 62 protrudes into a hole 64 of a side plate of wrapper
26. A lower edge 66 of catch 62 engages the lower edge of hole 64,
which limits the extent to which wrapper 26 can move away from base
24 once the wrapper is in place. Providing catch 62 with a tapered
upper edge 68 and staggering the positions of catches 62 relative
to lead-ins 50 (i.e., the catches and lead-ins are not directly
across from each other) allows wrapper 26 to flex and snap into
place by lowering wrapper 26 between catch 62 and lead-ins 50
during assembly.
This snap-in feature is further illustrated in the embodiment of
FIG. 6B, wherein a lead-in 50' replaces lead-in 50 and is
positioned closer to rim 56 to ensure more positive engagement
between catch 62 and wrapper 26. Staggering the positions of
catches 62 and lead-ins 50' allows the positioning of the catches
and lead-ins such that a greater spacing 70 exists between
peripheral rim 56 and a distal edge 72 of catch 50' than a spacing
74 between rim 56 and a shoulder 76 of lead-in 50'. Yet, the
wrapper's flexibility still allows wrapper 26 to snap into
position.
To hold corner panels 36, 38 and 40 in place, another catch 78
extending from rim 24 protrudes through a hole 80 in those corner
panels, as shown in FIGS. 2 and 3. Side panel 28 and corner panel
42 are each somewhat unique as will further be described below.
In a currently preferred embodiment, catch 78 protrudes much
farther from rim 24 than does catch 62 and includes an upper
surface that has a vertically extending lip 83. At assembly, the
hole 80 of each of these corner panels is engaged over a
corresponding catch 78 and is rotated to the vertical position
illustrated in FIG. 3. Once the remainder of wrapper 26 is
assembled, the substantial protrusion of catches 78 provides a very
positive, solid connection between base 24 and the corner panels.
However, in the rare event that it becomes necessary to remove a
side panel to corner piece after assembly, such removal can be
accomplished by the simple expedient of disengaging the catches 62
and/or 78 from the hole in the wrapper or corner panel in which
they reside.
To hold the sides of wrapper 26 together with a minimal number of
screws (if any), the wrapper's various side and corner panels are
interconnected by vertically sliding fits between mating edges of
adjacent panels. Referring to FIGS. 2 and 7, for example, the
vertical edges of side panel 30, like those of side panels 32 and
34, are roll formed (or otherwise formed) to create two generally
L-shaped edges 84 and 86. One or more corner panels also have their
vertical edges roll formed (or otherwise formed) to create edges
adapted to receive the L-shaped edges of an adjoining wrapper
panel. Corner panel 36, for example, includes edges 88 and 90.
Mating edge 88 of corner panel 36 engages edge 86 of side panel 30
to create a vertically sliding fit 92, referred to as a slip seam,
between the two.
To inhibit side panel 30 from horizontally separating from corner
panel 36, edge 88 is formed to wrap at least partially around and
capture the L-shaped edge 86 of side panel 30, as is the case with
side panels 32 and 34 and their interaction with the corner panels
between which they reside. More specifically, edge 88 includes a
first segment 94 and a second segment 96 that restrains and limits
the movement of edge 86 of side panel 30 in a first horizontal
direction. Further, edge 88 includes a third segment 98 and a
fourth segment 100 that restrains and limits the movement of edge
86 of side panel 30 in a second horizontal direction generally
perpendicular to the first direction.
Referring to FIGS. 7 and 8, forming a series of dimples 102 along
vertical edge 84 or 86 of a side panel such as side panel 30
creates a corresponding series of protrusions 104 that enhance the
vertical grip between the side panels and corner panels of wrapper
26. Protrusions 104 are spaced apart and face in opposite
directions, so that as edge 86 is slid vertically downward within
the confines of edge 88 of a corner panel, the inner surfaces of
edge 88 engage dimples 104 and then urge into a more coplanar
orientation, which causes resilient localized bending in the sheet
metal of edge 86. The resilience of the sheet metal acting upon
protrusions 104 maintains horizontal pressure between protrusions
104 and the inner surfaces of edge 88. The horizontal pressure
creates a frictional force that tightens the sliding fit between
edges 86 and 88 and results in a strong and rigid unit wrapper
26.
In assembling outdoor section 10, compressor 14 and coil 16 are
generally the first main components to be installed on base 24. In
some cases, one or more plastic spacers 106, such as the one shown
in FIGS. 1, 2, 9 and 10 can be attached to coil 16 to ensure
adequate space for airflow between coil 16 and the adjacent wrapper
26 and, when outdoor section 10 is part of a heat pump system, to
inhibit frost/ice bridging between the wrapper and coil. Also, if
coil 16 includes spine fins 108, ensuring such space between coil
16 and wrapper 26 may help prevent wrapper 26 from crushing the
fins either during or after assembling the unit.
In a currently preferred embodiment, spacer 106 comprises a unitary
plastic injection molded piece having a head 110 and an anchor 112
at opposite ends. Head 110 is adapted to abut an inner face of a
side panel, and anchor 112 engages coil 16. In some embodiments,
spacer 106 attaches to coil 16 by forcing anchor 112 between the
spine fins 108 of two adjacent coil wraps or tube sections 114 and
116 of coil 16. Anchor 112 firmly engages the spine fins 108 of
tube sections 114 and 116 and thereby holds spacer 106 in place.
Head 110 preferably includes a tapered surface 118 that can help
redirect a lower edge of a side panel away from coil 16 as the
panel is being lowered into position during assembly.
Assembling the side and corner panels to base 24 preferably follows
the suggested steps illustrated sequentially in FIGS. 11-19. In
FIG. 11, corner panel 36 is installed with hole 80 being slipped
around catch 78 in a manner previously explained with reference to
FIGS. 2 and 3. In a similar manner, corner panel 38 is installed
next, as shown in FIG. 12. Next, side panel 30 is vertically slid
downward into position between corner panels 36 and 38, as shown in
FIG. 13, having been piloted into final position on base 24 by
lead-ins 50 and alignment tabs 58 as earlier described. At this
point in the assembly process, side panel 30 and corner panels 36
and 38 are generally well supported. The vertical edges of side
panel 30 are fully engaged in the mating edges of corner panels 36
and 38, catch 62 has side panel 30 snapped into position between
rim 56 and lead-in 50, and the lower ends of corner panels 36 and
38 engage their respective catches 78.
Assembly may continue by installing corner panel 40, as shown in
FIG. 14, and then sliding side panel 32 between corner panels 38
and 40, as shown in FIG. 15. Next, in FIG. 16, corner panel 42 is
installed on the base. Because of its unique geometry and function,
corner panel 42 latches into base 24 in a manner different from the
other corner panels and has a unique seam 42a that is best
illustrated in FIG. 21 which is discussed below.
Next, side panel 34 is slid into position between corner panels 40
and 42, as illustrated in FIG. 17, and side panel 28 is engaged
between corner panels 36 and 42, as shown in FIG. 18 and as will
subsequently be described. FIG. 19 shows a front view of how a side
panel (e.g., side panel 32) is slid into position between two
supporting corner panels (e.g., corner panels 38 and 40).
Once base 24 and wrapper 26 are assembled to the extent shown in
FIGS. 2 and 18, an orifice member 120 can be installed on top of
wrapper 26, as shown in FIGS. 1 and 20. Orifice member 120 defines
a fan orifice 122. In operation, fan 18 draws outside air through
louvers 124 in the side panels of wrapper 26 and across coil 16 so
as to exchange heat with the refrigerant inside the coil.
Fan 18 is driven by a motor 126 that is supported by a frame 128
attached to orifice member 120. Frame 128 comprises two
substantially identical sheet metal frame members 130 that can be
attached to each other in a conventional manner, such as by way of
screws, welding, etc. Together, frame members 130 provide four tabs
132 that are screwed or otherwise attached to motor 126 to support
and position motor 126 within orifice member 120 and four other
tabs 134 that attach to orifice member 120 so as to secure frame
128 thereto. Each frame member 130 includes two flange surfaces 134
and 136 for stiffness and for providing a surface area upon which a
top cover 138 rests and finds support.
Top cover 138 rests atop frame 128 and provides a protective shield
over fan 18. As fan 18 draws outside air into cabinet 12 and across
coil 16, openings 140 around the perimeter of cover 138 allow fan
18 to discharge the air back to the ambient, generally in a
direction which is upward and away from the cabinet sides. A lower
rim 142 of cover 138 attaches to wrapper 26 by way of screws or
some other appropriate means for attachment. In some cases, an
outer rim 144 of orifice member 120 lies between cover rim 142 and
the upper edge of wrapper 26, so top cover 138 engages orifice
member 120.
Since outside air is drawn into cabinet 12, moisture can be drawn
in as well. To prevent that moisture from contaminating electrical
components 146 associated with air conditioner 10, components 146
are housed inside a compartment 148 adjacent corner panel 42 and
underneath top cover 138, as shown in FIGS. 1, 2 and 21. Components
146 are schematically illustrated to represent any type of
electrical component including, but not limited to, relays, motor
starters, motor starting capacitor, wires, control circuits,
electrical terminals, etc. Corner panel 42 shelters the electrical
components 146 from moisture that may be inside cabinet 12, while
an outer access panel 150 fastened to corner panel 42 provides
shelter from air outside of cabinet 12. Thus, in this example,
corner panel 42 serves as an "interior panel," whereby panel 42 is
exposed to an interior 152 of cabinet 12 and is at least partially
sheltered from an exterior 154 of cabinet 12 (see FIG. 2).
Referring to FIGS. 2 and 21, components 146 can be mounted inside
compartment 148 by various means. For example, components 16 may be
readily attached using a screw 156 or some other type of fastener
(e.g., a self-tapping screw, sheet metal screw, rivet etc.). In a
currently preferred embodiment, corner panel 42 is provided with
closed screw-receiving dimples 154 at numerous preplanned locations
to accommodate various component-mounting arrangements for various
air conditioner models. Depending on the model of a particular
unit, some dimples 154 may receive a screw 156 and others may be
left unused. If left unused, dimple 154 remains watertight to help
prevent moisture inside cabinet 12 from leaking into compartment
148.
Dimples 154 are created by a conventional forming tool 158, as
shown in FIG. 21. Dimples 154 are sufficiently deep and narrow, so
that as screw 156 is turned into dimple 154, the threads of the
screw bite into and grip the inner walls of the dimple, as
indicated by screw 156'. Further tightening of the screw forces the
screw to break through the bottom of the dimple, as indicated by
screw 156''. To hold the screw in place, a nut may be installed on
the screw, or the thread marks left on the inner wall of the now
open dimple may be sufficient to hold the screw.
Still referring to FIGS. 2 and 21 but additionally to FIG. 18, side
panel 28 has a first vertical edge 28a which is configured in the
same manner as the vertical edges of side panels 30, 32 and 34. The
other vertical edge 28b of side panel 28 is configured differently
and has a lip 28c that becomes ensconced in the vertically running
opening at end 42a of corner panel 42 when panel 28 is assembled to
the remainder of the wrapper.
Referring primarily now to FIG. 18, on assembly of side panel 28 to
the remainder of the wrapper 26, vertical edge 28a of side panel 28
is inserted into the accommodating vertically running opening in
edge 36a of corner panel 36. Such engagement results in the
creation of what is essentially a pinless hinge. In that regard,
once edge 28a of panel 28 is engaged within accommodating
vertically running opening at the edge 36a of corner panel 36,
panel 28 is swung inward, in the direction indicated by the arrow
28c in FIG. 18, until lip 28d of panel 28 enters the vertically
running opening in end 42a of corner panel 42. Edge 28b of side
panel 28 is then secured to end 42a of corner panel 42 using one or
more fasteners, such as sheet metal screw 159.
Referring primarily now to FIG. 2, because of the unique
arrangement and function of side panel 28, base 24 is somewhat
modified on the side of it which supports panel 28. In that regard,
the lower edge of panel 28 rests on supports 24a which are integral
with and extend inwardly from rim 56 of base 24 at a horizontal
height coincident with the height of the upper edge of rim 56.
Supports 24a therefore support side panel 28 on base 26 while at
the same time accommodating the ability of panel 28 to swing
outward without interference from base 24. Panel 28 is therefore
easily removed and access to the interior of wrapper 26 is thereby
gained. Because supports 24a are employed in support of panel 28,
alignment tabs 58 and catches 62 are dispensed with on this side of
base 24.
Referring now to FIG. 22, temporarily mounting the outdoor section
to a conventional shipping pallet 160 may help in transporting the
unit before the outdoor section is permanently installed at its
installation site. To that end, one or more breakaway shipping tabs
162 extend integrally from the perimeter of base 24, while a
fastener 164 anchors tabs 162 to pallet 160. Fastener 164 is
schematically illustrated to represent any type of conventional
fastener including, but not limited to, a staple, nail, screw, etc.
To remove the outdoor section from pallet 160, tabs 162 are severed
by cutting, tearing, prying, or breaking, which releases base 24
and leaves a now scrap portion 162' of tab 160 still attached to
pallet 160. Alternatively, the staple, nail or screw holding the
unit to the pallet can itself be removed leaving the tabs intact.
If so, the tabs can be used to secure the unit to the surface on
which it is ultimately installed.
Also to be noted with respect to FIG. 22, it is contemplated that a
radio frequency identification device may be embedded/molded into
base pan 24. Device 166 is a relatively inexpensive device capable
of transmitting information relating to the specific outdoor
section 10 in which device 166 is embedded. Such information might
include the serial number of the unit, model, information relating
to the refrigerant it is charged with, date of manufacture and
other such information that may be useful with regard to servicing
the unit.
Because device 166 will have been molded into/embedded in base pan
24 prior to the assembly of outdoor section 10 in the factory and
because outdoor sections 10 are, generally speaking, built from the
base pan up, device 166 can contain additional information that is
likewise readable by receiving devices positioned on the assembly
line within the factory. As such, device 168 in FIG. 22 is
representative of both a service device used in the field and a
device that might be mounted on the assembly line in the factory
where outdoor section 10 is manufactured.
Information used in the manufacturing process within a factory
might include model number-related information that would be read
as the base pan moves down the assembly line. Such model-related
information can be used to trigger the display of information or
instruction to assemblers with regard to the model being configured
and the particular components/pieces that are to be used in
assembling that particular model. As will be appreciated, such
information might also be of value and be used in the context of
warehousing, shipping and distribution of outdoor units. Overall,
by the use of a relatively inexpensive and long-lived radio
frequency transmitting device embedded in base pan 24, which may be
self-powered and triggered in response to a query from device 168,
a wealth of information is made available from the start of
assembly of individual outdoor section 10 to the service of that
outdoor section years later in the location in which it is
installed.
Referring now to FIG. 23, the control box corner panel to base pan
latching arrangement is illustrated. As has been noted, corner
panel 42 is of a unique geometry and function in that it cooperates
in the definition of the walls of compartment 148 in which control
components are housed. As has also been noted, corner panel 42
latches into base 24 in a manner different from the other corner
panels of cabinet 12.
In that regard, in order to latch panel 42 to base pan 24, panel 42
is aligned with the base pan such that surface 202 of panel 42 is
adjacent recessed surface 204 of cleat 206 on base pan 24. In that
position, notch 208 of surface 202 rests over horizontal surface
210 of cleat 206. At the time such alignment is made, post 212 of
base pan 24 is generally in alignment with but does not protrude
through slot 214, which is defined in surface 202 of corner panel
42, at end 216 thereof.
With corner panel 42 so aligned, panel 42 is moved horizontally
away from surface 204 of cleat 206 in the direction indicated by
arrow 218. As corner panel 42 is so moved, notch 208 moves off of
cleat 206 and post 212 penetrates slot 214 and protrudes
therethrough at end 216 thereof. This position is generally
illustrated by the phantom lines in FIG. 23.
Panel 42 is then moved horizontally in the direction indicated by
arrow 220, such direction being at a 90.degree. angle to the
direction indicated by arrow 218. In the process of moving panel 42
in the second horizontal direction, indicated by arrow 220, post
212 slides within slot 214 and comes into abutment with end 222 of
slot 214. End 222 of the slot therefore limits the horizontal
movement of corner panel 42 in the direction indicated by arrow
220.
At the same time and because the lower edge of surface 224 of
corner panel 42 will have originally been positioned over surface
226 of resilient tab 228 on base pan 24, surface 224 will have
depressed resilient tab 228 in the process of moving in the
direction of arrow 220 and will have moved just past the end 230 of
tab 228 when post 212 comes into abutment with end 222 of slot 214.
Once the lower edge of surface 224 moves past end 230 of resilient
tab 228, tab 228 springs upwardly to effectively and securely latch
corner panel 42 in position on the base pan.
It is to be noted that one or more others of cleats 206, notches
208, slots 214 and posts 212 may exist on or in base pan 24 and
corner panel 42 and be similarly arranged with respect to surface
202 of the corner panel. It is further to be noted that base pan 24
may include other cleats, posts and alignment tabs. These include
post 232 which comes to protrude through slot 34 of surface 224 of
corner panel 42 as the corner panel moves in the direction of arrow
220. Cleat 236 similarly positions, abuts and secures surface 238
control panel 42 into position on base pan 24 both in the initial
assembly process and once corner panel 42 is latched into
place.
Although the invention is described with reference to a preferred
embodiment, it will be appreciated by those skilled in the art that
other variations are well within the scope of the invention. For
example, vertically sliding fits, such as fit 92, can be applied to
any number of adjoining wrapper panels. In some embodiments of the
invention, all the wrapper panels are joined in this manner, as
shown in FIG. 2. In other embodiments, some wrapper panels are
connected by a vertically sliding fit, and others are connected by
screws in a more conventional manner. It should be appreciated by
those skilled in the art, that alternatively, the L-shaped edge
could be on corner panel 36 and the edges of side panel 30 could be
similar to edge 88. It should also be appreciated, that wrapper 26
could have more or less than the eight panels shown in the drawing
figures. For example, it would be well within the scope of the
invention to provide a wrapper with just four side panels that
interconnect directly with each other without intervening corner
panels. Therefore, the scope of the invention is to be determined
by reference to the claims, which follow.
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